SUSPENSION 4-] S SPECIFICATIONS AND SERVICE DATA 1. Suspension........ © COMPONENT PARTS 1. Suspension W SERVICE PROCEDURE On-car Services Front Transverse Link Front Ball Joint Front Strut Front Stabilizer Front Crossmember Rear Trailing Link Lateral Link Rear Strut ©EnOnrona 10.Rear Crossmember (FWD Model) 11.Rear Crossmember (AWD Model) T DIAGNOSTICS 1. Suspension Page eon 24-1 [stay 4. Suspension ( SPECIFICATIONS AND SERVICE DATA 1. Suspension A: SPECIFICATIONS 1. STABILIZER ‘Bar dia. mm (in) Front Rear 19 (075) = 4 door Sedan 49075) 493051) 4 door Sedan TURBO 19 (0.75) 17 (0.87) 5 door 49075) = 5 door TURBO 19075) 17 (087) B: WHEEL ALIGNMENT (common difference: +1") 1 or Soden Seon Fo | _awo | wuneo|—pwo | —awo “Tuna ———— ow ww | ow | oo | oe cane a a Front {Ten 028 (00.12) Ton angle: 0°09" (when toe-in is -9 (-0.12)} mam (in) Toe-out angle: 0°09" {when toe-out is 3 (0.12)] Kingpin angle veer | twos | 140’ | 1420" | twos | 1440 Wheet arch height (tolerance: 732 mm (EZ in] | 381 (18.00) | 391 (15:39) | 371 (14.61) | 381 (18.00) | 391 (15.39) | 971 (14.61) mam (in) [camber ; ; a = = ; eT “ ass | ro | o's | 50 | =r" Toe: ‘043 (00.12) Toe-in angle: -0°09' [when toe-in is -8 (-0.12)) Rear mm (in) ‘Too-out angle: 0°09" [when too-out is 3 (0.12)] [Wheel arch height tolerance: *33 mm ("331 ip] | 968 (14.49) | 379 (14.92) | 363 (14.29) | 378 (14.88) | 987 (15.24) | 363 (14.29) Toon NOTE: e Front and rear toe-ins and front camber can be adjusted. If toe-in or camber tolerance exceeds specifications, adjust toe-in and camber to the middle value of specifications. @ The other items indicated in the specification table can- not be adjusted. if the other items exceeds specifications, check suspension parts and connections for deformities; replace with new ones as required z llWHEELS AND AXLES 4-2 Page essed ad S SPECIFICATIONS AND SERVICE DATA... 1. Wheels and Ax\es....... COMPONENT PARTS 1. Front Axle 2. Rear Axle W SERVICE PROCEDURE 1. Front Axle 2. Rear Axle (AWD Model) 3. Rear Axle (FWD Model) 4. Front and Rear Drive Shafts... 5. Full Wheel Cap 6. 7, 8. 9. Steel Wheel and Tire . Wheel Balancing . Installation of Wheel Assembly to Vehicle . Tire Rotation 10. "T-type" Tire4-2 [s1a1) 1. Wheels and Axles SPECIFICATIONS AND SERVICE DATA 1. Wheels and Axles A: SPECIFICATIONS 1. TIRE AND WHEEL SIZE Poo. Rim offset PCD. Tire size Rim size mm (in) mm (in) 165/80R19 82S pee 13x 6.008 50 (1.97) Front and Rear 175/70R14 BAT, 84H 14x68 Wald 55 (2.17) 205/55R15 67V 15x 6) 55 (2.17) 100 (3.94) dia, T125/70015 18x aT 53 (2.08) Type tire T125/70016 16x 4T 50 (1.97) T135/70016 16x4T 50 (1.97) NOTE: “Tlype™ tire for temporary use is supplied as a spare tire. 2. TIRE INFLATION PRESSURE Tire inflation pressure kPa (kg/em®, psi) Tire size Light load Full oad 4 door Sedan ae Ft: 220 (2.2, 32) 5 door pens ear Fr: 200 (2.0, 29) 175/70R14 84T, 84H 2 4 door Sedan Turbo Fi: 230 (23, 38) 5 door Turbo ee Fr: 220 (2.2, 32) T125/70015 7125170016 420 (4.2, 60) 7198/70016SPECIFICATIONS AND SERVICE DATA [s1a3] 4-2 3. FRONT DRIVE SHAFT ASSEMBLY = ‘Type of axle shaft e eee =| | , wea |} eyes _4-2 [s1a4) SPECIFICATIONS AND SERVICE DATA 1, Wheels and Axles 4. REAR DRIVE SHAFT ASSEMBLY (AWD MODEL) SHAFT | Type of axle shaft assembly |" _} 'No. of identification paddings on shaft None 2 (Two) e2Ac-RH a = -=8- dentition padaings BeAC-LH 78N¢ ce 5. APPLICATION TABLE Front drive shaft Model Power unit Rear drive shaft SMT 4aT FWD 1600 ce B2A0-23 B2A0-25 FWD. 1800 co a7AC-23 B7AC-25 i) 1600-1800 ce B2AC-25 B2AC-25 79AC ‘AW 2000 ¢2 Turbo B7AC-25 B2AC-RH, 82AC-LH 4SPECIFICATIONS AND SERVICE DATA B: SERVICE DATA Wheel balancing Standard [Service limit Dynamic unbalance Loss than § 9 (0.18 oz) 1. STEEL WHEEL Balance weight part number (For stee! wee!) iene! 2eO1AAOOT ~ 5 (018) | 2B10TAAOTT 100.38) 2B10TARO2t 150.53) 2BTOTAROST 20071) 2B10TAAOAT 25 088) 2BTOTAAOSI 30 (1.06) 2BT0TAAOI 35 (123) 2eI01AAOT onan 2BI01AA0BI 45 (1.59) 26101AA01| 50 (1.76) 2BTOTAATOT 55 (1.94) 2B101AATIt 60 @.12), 2, ALUMINUM WHEEL Balance weight part number (For aluminum whee!) ‘Weight 9 (02) 29141GA462 5 (0.18) 23141GA472 10 (0:36) 29141GA482 45 (0.59) 231416491 201071) 23141GA501 25 (0.88) 2a41GASTI 30 (1.06) 2et41GAS21 35 (1.23) 2a141GAS31 4011.41) 2aVa1GASAt 45 11.59) 23141GA551 5011.76) = 5511.98) 2a141GAST1 602.12)4-2 wanz] 4. Front and Rear Drive Shafts SERVICE PROCEDURE 4. Front and Rear Drive Shafts A: REMOVAL 2. REAR DRIVE SHAFT 1) Disconnect ground cable from battery. 2) Lift-up vehicle, and remove rear wheel cap and wheels. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may dam- age wheel bearings. 3) Unlock axle nut. 4) Loosen axle nut using a socket wrench CAUTION: Do not remove axle nut. 5) Remove ABS. sensor clamps and parking brake cable bracket. 6) Remove bolts which secure lateral link assembly to rear housing ‘CAUTION: Discard old self-locking nut. Replace with a new one. 7) Remove bolts which secure trailing link assembly to rear housing CAUTION: Discard old self-locking nut. Replace with a new one. Non TURBO model: Perform step 8). 8) Remove DOJ from rear differential using tire lever. NOTE: The side spline shaft circlip comes out together with the shaft CAUTION: When removing the DOJ from the rear differential, fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder.SERVICE PROCEDURE [w4az] 4-2 4. Front and Rear Drive Shafts Z\ Qe TURBO model: Perform step 9). IN XO D Test 9) Remove DOJ from rear differential using ST. = eet ST 28099PA100_ DRIVE SHAFT REMOVER NOTE: Left spline end of DOJ is removed together with circlip. Do not remove right circlip attached to inside of differential. CAUTION: Be careful not to damage side bearing retainer. Always use bolt as supporting point for ST during removal. ST 28099PA100 DRIVE SHAFT REMOVER 10) Remove axle nut and drive shaft. If it is hard to remove, use ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER S12 _ 927140000 PLATE CAUTION: © Be careful not to damage oil seal lip when removing rear drive shaft. When rear drive shaft is to be replaced, also replace inner oil seal with a new one.STEERING SYSTEM 4-3 Page S SPECIFICATIONS AND SERVICE DATA 1. Steering System. COMPONENT PARTS...... 4.Steering Wheel and Column i) 2. Power Steering System. 3. Power Steering Oil Pump 4, Manual Steering Gearbox W_ SERVICE PROCEDURE 1. Supplemental Restraint System “Airbag” (UMD 2. Tilt Steering Column 3, Steering Gearbox (Fower Steering System) [LHD model] 4, Steering Gearbox (Power Steering System) [RHD model] 5. Steering Gearbox (Manual Steering System) 6. Control Valve (Power Steering Gearbox) [LHD model] 7. Control Valve (Power Steering Gearbox) [RHD model] 8. Pipe Assembly (Power Steering System) 9. Oil Pump (Power Steering System) 10. Power Steering Fluid T DIAGNOSTICS 1. Power Steering PRECAUTION FOR SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” The Supplemental Restraint System “Airbag” helps to reduce the risk or severity of injury to the driver in a frontal collision The Supplemental Restraint System consists of an airbag module (located in the center of the steering wheel), sensors, a control module, warning light, wiring harness and roll con- nector Information necessary to service the safety is included in the “5-5. SUPPLEMENTAL RESTRAINT SYSTEM" of this Service Manual WARNING: To avoid rendering the Airsag system inoperative, which could lead to personal injury oF death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU desler. «Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Airbag system. ‘All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insulation. Do not use electrical test equipment on any circuit related to the Sup- plemental Restraint System “‘Airbag”.4-3 [S100] SPECIFICATIONS AND SERVICE DATA 1, Steering System 1. Steering System A: SPECIFICATIONS TURBO Model Non TURBO LHD RAD Minimum turning radius me) 31067 sac | sacra) Steering angle (inside-Ouside) 7s — Re ue —aor | es — oe With AIRBAG 985 (5.16) Whole system | steering whee! diameter mm (in) i: 370 (14.57) Without AIRBAG 375 (1476) Overall gear ratio. eater 165002) 167 (30) 1528) Type Rack and pinion, integral Gearvox [Backlash 0 (Automatically adjustable) Valve (Power steering system) Rotary valve Type Vane pump il tank installed on pump Output em? eu inyrev. 72 (0.439) ; 7385 796 pump (poner |Pelet esse kPa (kalem®, pai) 6.75 (65, 924) Paonia euirony steering Dropping in response fo increased engine | Constant flow system) Hydrauie ud contro} Tevolutions ‘ype 1,000 rpm: 7 (74, 62) Hydraulic tuld (US qt, Imp a’) Bee 774,62) Range of revolution om 500 — 7,500 Revolving direction Clockwise Working tid | Name ATE DEXRON Il oF HE (Power steering —_| capacin tank 03 (03,03) system) Pact Total” (US at, Imp at) 07 (07, 08)SPECIFICATIONS AND SERVICE DATA [steo] 4-3 1. Steering System B: SERVICE DATA Non TURBO TURBO Model LH HD LAO RHO [steering wheel___[Free play mm (in) 47 (0867) Inner tire & whee! 75 as" 65 Turning angle : Outer tire & wheel se aor sie learance between steering whee! an steering shatt | Clearance between steering whee! and 3.0 (0.118) Sliding resistance N (kg, 1b) 240.3 (245, 640) or less are 018 (0.007 ]o4s (oo17]o19 (o007s)/048 (oor77) Rack shat play in| RlahHurm storing OS ee tose | or teas |r lees radial direction mmm (in)|Loftturn steering [948 (0.0177)]0.19 (0.0076)/045 (00177)/0.19 (0.0075) Steering gearbox ork or less or less or less Input shaft play ram in) In radial direction 0.18 (0.0071) or less In axial direction 0.4 (0.004) oF less [Within 30 mm (1.18 In) from rack center in straight ahead ‘Turning resistance N (kg, 1b) | position: Less than 11.18 (1.14, 2.51) Maximum allowable value: 12.7 (1.3, 29) Oil pump (Power Pulley Regular pressure kPa (kg/cm’, psi) 981 (10, 142) or less. ‘At standstill with engine 4 2,7.) or oss Steering whee! Jialing on a concrete road __N (kg, 1b) cece tor (omer see [ren cone ing system standstill with engine 47 (15, 3) oF less eae stalled on a concrete road__N (kg 1) AS) C: RECOMMENDED POWER STEERING FLUID ing fluid Manufacturer BP. [CALTEX ATE DEXRON II or [CASTROL ATE DEXRON IIE MOBIL SHELL TEXACO, Recommended power st4-3 (c201] COMPONENT PARTS 2, Po wer Steering System 2. Power Steering System 1. LHD MODEL 7 Tightening torque: Nem (kg-m, f-1b) Tt: 5.41.5 (0.55+0.15, 4.01.1) 12: 1343 (1340.3, 9.4422) Th: 1545 (15405, 10.843.6) Ta: 20.1 2.5 (2.05 40.25, 14.8:41.8) TS: 2242 (2.20.2, 15.941.4)COMPONENT PARTS [c201] 4-3 @ Clamp @ Adapter @ Hose bracket @ Pipe c & Pipe D © cap @ Strainer @ tank ol pump Pal Bel cover Bracket Pie © Clamp plate 228088 3 3 ® Universal joint ® Dust seal ® Cring Oil seal Valve housing Packing Seal ring Pinion and valve ASSY Oil ses Back-up washer Ball bearing ‘Snap ring @ Sleeve eseeesese eo g ‘Adjusting screw Lock nut Housing ASSY Back-up washer Oil seal Adapter Clamp Pipe A Pipe B Lock washer Tie-rod Boot Cotter pin Castle nut Dust seal Tie-rod end Spacer Cirelip Rack stopper Oil seal Rack bushing O-ring Rack Piston ring @ Tank bracket © O-ring SVSGHSSOSSOSSHSSSSHOSSOSHOG4-3 [202] COMPONENT PARTS 2. Power Steering System 2. RHD MODEL canoe Tightening torai telby TH: 7442.0 (0.75 40.2, 5.4414) Te 192919203 84322) T10: 6410 (65+ 1.0, 477) Tit: 70410(8010, 5827)COMPONENT PARTS [c202] 4-3 ———— a Storing Syston, @ Pipe Om @ Pipe @ Tie-rod RH ee ® Lock washer @ strainer @ Lock nut tein @ Adjusting scrow a @ Sprin oon & Stoeve ae @ PipeB @ Belt cover "pe fe funiseerfear 8 Poa fe loeieer lousing ASSY @ Valve housing ® Adapter ® Y-packing ® Clamp ® Ball bearing @ Back-up washer ® Spacer @ Oieea ® Pinion 20) ® shim © o-ring {8 Cotter pin © Oil seal ® Casto nut ® Y-packing @ Dust seal @ Bush 8 Cip @ Holder @ Tierod end © Tie-rod tH Clip © oning @ Boot @ Tank bracketBRAKES 4-4 Page S SPECIFICATIONS AND SERVICE DATA 1, Brakes — © COMPONENT PARTS Front Disc Brake Rear Disc Brake Rear Drum Brake Master Cylinder Brake Booster ABS. System Hill Holder ._ Parking (Hand) Brake W SERVICE PROCEDURE Front Disc Brake Rear Disc Brake Rear Drum Brake Parking Brake (Rear Disc Brake) Master Cylinder Brake Booster Brake Hose Hill Holder Parking Brake Lever 10. Parking Brake Cable 11. Air Bleeding 12. Brake Fluid Replacement 43. Proportioning Valve 14. ABS. Sensor 15. Hydraulic Unit for A.B.S. System 16. A.B.S. Control Module 17. G Sensor for A.B.S. System 18. Brake Hose and Pipe QIN T DIAGNOSTICS 1. Entire Brake System 2. Hill Holder 2 eo 9 9 eNegsens ©ernopaens PRECAUTION FOR SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” The Supplemental Restraint System “Airbag” helps to reduce the risk or severity of injury to the driver in a frontal collision, ‘The Supplemental Restraint System consists of an airbag module (located in the center of the steer- ing wheel), sensors, a control module, warning light, wiring harness and roll connector, Information necessary to service the safely is included in the "5-5. SUPPLEMENTAL RESTRAINT SYSTEM" of this Service Manual WARNING: ‘© To avold rendering the Airbag the event of a severe frontal c ARU dealer. ‘# Improper maintenance, including Incorrect removal and Installation of the Alrbag system, can lead to personal Injury caused by unintentional activation of the Airbag system. ‘# All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insu- lation. Do not use electrical test equipment on any circuit related to the Supplemental Restraint System “Airbag”. lem inoperative, which could te (on, all maintenance must be performed by an authorized SUB- i4-4 [s1A1) SPECIFICATIONS AND SERVICE DATA 1, Brakes: 1. Brakes A: SPECIFICATIONS 1, MODELS WITH A.B.S. 4 ode {Door Sedan S boon Engine (6) 1600 1600 1200 [1800 1600 1000 Driving system FH. AWD Fwo aN. olafexeytavalaloxfajfa Type Disc (Floating type, ventilated) tet de dante no ean Diss hkness x Outer diameter 24x 290 (094 x 1024) rm tn Front [Eectve ayinder brake diameter 53.97 (2.125) mm (in), Pad dmeaions (length x width x. Monat x 1124 443 110 (649 4.744 0.430) rm Gearanceadjusiment Avtomatis eusiment Type Dise (Floating type) Ete decane 20 (000) Dio tioess x Outer diameter 10 266 (039 x 1047) en () Rear | Effective cylinder brake diameter 34.93 (1.375) 38.10 (1.5000) mtn ad dimerlons engi x wich 024 98.7 x 100 (2.608 x 1.927 0.96) oom Clearance adjustment Automat ausimentr SPECIFICATIONS AND SERVICE DATA [stat] 4-4 Wedel “oor Sedan 3000 Engine 2) i600 1600 ‘00 | 1600 1600 1200 Driving eystom wo AWD Pwo. A xolalefafalafepala Tipe Mechanical on ear brakes, drm in dee herve un dar 17060) Parking | Lining dimensions rake length x width x . (ength x width 162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126) thickness) som (in p Clearance adusment Wanoa aust ype Tandem Ettectve diameter sao mm (in), Master cylinder | Reservoir type Sealed type Brake tid reservoir capacity 190 (11.59 em? (eu in) vpe ‘Vacuum suspended Brake bi booster |Etecve damaer 120 + 205 7.09 + 807) propor [Si point "oot (0,280 tioning |___ KPa (ko/em?, psi eared valve Reducing ratio 04 Brae ine Dual creut oyster ABS oP4-4 [812] SPECIFICATIONS AND SERVICE DATA {Brakes 2, MODELS WITHOUT A.B.S. Tose 1 boo Stan Seer Engine) veo [1800] i600 [e00| e00 [00 | 1600 [on ring ayo wo 7A rb AWD a[olelalxfalalmjala[xlala Ti Bie sing ype vented Eteive dee danowr | 198 a te | ae 210,62 m 210,627 ex Dice hres x Outer wwaaee Be sever | ets, sexajonexioae |M2,| sexatonenioan 200 Front Frett _Etccve ain diameter soar a9 om Pad aivesios (ona wath tent tia ak9 x 110 (4484 1744 0480) rm Glearance austront Feats ajo Type Drum (Leading-Trailing type) etc am an vate Etetve crn nas ee | ras ‘20s rear peero (ors) esere ers brake mm (in) Lining dimensions (length x width x thickness) mm (in) 218.8 x 35.0 x 4.1 (861 x 1.378 x 0.161) [Clearance adjustment ‘Automatic adjustment aSPECIFICATIONS AND SERVICE DATA [s1az] 4-4 1. Brakes eas) Model 1 Boor Sedan S door Engine (62) soo [1600] 1600 | 1000| 1600 [000] 1600 | 1800 Driving system FWD AWD FWD ‘AWD a[xlela}xfalalxfealalelala [Tivo Mechanical on rear brakes, drum in dae Effective drum diameter 2208 0) ‘mm (in) W Parking |Lining dimensions brake | length x width x 2188 x950x41 (61x 1978 x enoth x 108 x 95.0 x 4.1 (861 x 1.978 x0:161) oom (i) Clearance adjusiment ‘Automatic adjustment Type Tandem Ete ameter mast oasre) Master wiieaor [Reservoir type Sealed type _ Brake fluid reservoir capacity 190 (1159) em? cu in) Tipe Vacuum suspended Brake Brake [ettective diameter 120 (908) co (i) Propor- [Split point 2,942 (300, «27) facet Pa (kgem?, ps valve [Reducing ratio oa Brake tne Dual cicultayatem4-4 [s1a3} SPECIFICATIONS AND SERVICE DATA 1, Brakes ( 3. TURBO MODEL [____ Mode! 4 Door Sedan 5 Door Engine (cc) 2000 Driving system ‘AWD TURBO Type Disc (Floating type, ventilated) Effective dise diameter mm (io) 228 (8.98) Disc thickness x Outer diameter 24 x 277 (0,94 x 10.91) mm (in) mm (in) Front [Effective eylinder brake | giameter 42.86 (1.6874) mm (in) Pad dimensions (length x width x. eee 11233 x 50.0 x 11.0 (4.42 x 1,969 x 0.433) nm (in) Clearance adjustment ‘Automatic adjustment Type Disc (Floating type) Eteete dian carat ae Disc thickness x Outer diameter 10 x 266 (0.39 x 10.47) mm (in) Rear [Effective cylinder brake | diameter 38.10 (1.5000) Pad dimensions (length x wiath x thickness) mm (in) 92.4 x 98.7 x 10.0 (9.638 x 1.927 x 0.994) Clearance adjustment ‘Automatic adjustmentSPECIFICATIONS AND SERVICE DATA tbe ) sia) 4-4 Model 4 Door Sedan 5 Door Engine (60) 2000 Driving system ‘AWD TURBO Type Mechanical on rear brakes, drum in disc teste ra danas 170 (662) Parking |Lining dimensions ake | ingthx width x . (length x width 162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126) thickness) rm (in Clearance adjusiment Manual adjustment Type Tandem ) Eeave dar 009 Master cylinder | Reservoir type ‘Sealed type Brake tud reservoir capacity 190 (1159) em (cu in) Type Vacuum suspended Brake booster |Etectve diameter 10 + 205 (7.09 + 8.07) Propor- | SPlit point : 41,961 (20, 284) toning KPa (kglem?, psi valve Reducing ratio o4 Brake tne Dual circuit system ABs oP4-4 [8180] SPECIFICATIONS AND SERVICE DATA 1. Brakes a : SERVICE DATA ITEM ‘STANDARD SERVICE LIMIT. Pad thickness [fntwciny back mata 47 mm (067 in) 7.5 mm (0.295 in) Front brake — 13-inch type: 18 mm (0.71 in) | Tinch type: 16 mm (0.63 in) 15:t4-inch type: 24 mm (0.94 in) | 16:14-inch type: 22 mm (0.87 in) Dise runout = (0.07 mm (0,000 in) Pad thickness aaa sear rue ete cen 415 mm (0.89 in) 6.5 mm (0.256 in) tear brake (Disc Pe) isc thickness 10-mm (0339 in) 8.5 mm (0895 in) Dise runout = 10.10 mm {0.0039 in) inside diameter 228.6 mm (9 in) 230.6 mm (9.079 in) Fear brake (Orum tyPe) Lining thickness 4.1 mm (0.161 in) 1.5 ram (0.059 in) Rear brake (Disc type 470 mm (6.68 in) 171 mm (6.73 in) parking) 3.2 mm (0.126 in) 115 mm [0.059 in) Parking brake Lever stroke 7 to 8 notches/T96N (20 k9.44 Ib) ‘Non TURBO model TURBO model { Without ABS. | WithABS. | WithowtABS. | WithaBs. || Brake pedal a Fluid pressure uN 874.8 kPa 770.8 KPa 770.8 KPa 7708 Pa Brake fluid stg 33h) | @S2kaiem?, | (7.86 kg/em?, | (7.86 kg/em*, | (7.86 ko/em’, pressure eg 126.8 psi) 414.8 psi) 414.8 psi) 1148 psit without engine DN 2267.4KPa_| 1,9038KPa | 1,9988KPa_ | 1,990.8 KPa. running (ootg, 66 th) | 2212 ko/em?, | (20.35 ka/om?, | (20.35 ka/em’, | (20:33 kofom, Brake booster o 3288 psit 269.1 psi) 269.1 psi) 289.1 psi) Brake fluid a ssieekPa | 5483.1kPa | 3.900aKkPa | 4,767.8 KPa Pressure with ty) | (6554 ko/em?, | (65.91 kglom?, | (40.78 kglem?, | (48.82 ko/em, fengine running o 7898 psi) 7950 psi) 5793 psi 6942 psi) ‘and vacuum at 667 kPa (500 2oAN aseiakea | 9,1146KPa | 88020KPa | 0.1146 KP: mma, 1969 | gouge g ip) | @526Ka/em?, | (82.9¢Kg/em?, | (9087 kglem", | (92.98 kglem’ into) 2 1.2124 psi) | 1.3216 psi) | 1,2893psi) | 1.921. psi) C: RECOMMENDED BRAKE FLUID FMVSS No. 116, fresh DOTS or 4 brake fluid CAUTION: © Avoid mixing brake fluid of different brands to prevent the fluid performance from degrading. ‘© When brake fluid is supplemented, be careful not to allow any dust into the reservoir. © Use fresh DOTS or 4 brake fluid when replacing or refilling the fluid. D: BRAKE FLUID LEVEL INDICATOR Reserve tank with level indicato Residual fluid quantity at light ON Approx. 80 cm? (80 cc, 4.88 cu in) Tank capacity 190 cm? (190 cc, 11.59 cu in)COMPONENT PARTS tc107] 4-4 4. Front Disc Brake 1. Front Disc Brake 2. TURBO MODEL ® Lock pin ® Bootring @ Lock pin sleeve ® Suprort @ Lock pin boot @ Padalip @ Caliper body ® Outer shim @ Air bleeder screw ® Pad iOulsice) z © Guide pin @ Pad (inside) 15:78:10 (8.01.0, 58:47) © Guide pin boot ® Inner shim © Piston seat ® shim @ Piston ® Disc rotor @ Piston boot @ DisccoverPEDAL SYSTEM AND CONTROL CABLES -5 S SPECIFICATIONS AND SERVICE DATA... 1. Pedal System © COMPONENT PARTS 1. Pedal (MT model) 2. Pedal (AT model) W SERVICE PROCEDURE....... A. POAL seeosssen : 2. Clutch Cable 3. Accelerator Cable 4, Speedometer Cable T DIAGNOSTICS 1, Pedal System and Control Cables on4-5 [s1A0} 1, Pedal System SPECIFICATIONS AND SERVICE DATA 1. Pedal System A: SERVICE DATA 1 — 3 mm (0.04 — 0.12 in) Brake pedal Free play [Depress brake pedal pad with a force of less than 10 N (1 kg, 2 Ib). Free play ‘At clutch pedal pad [5 — 15 mm (0.20 — 0.9 in) Clutch pedal LHD: 145 — 150 mm (5.71 — 5.91 in) Full stoke Atclutch pedal pad | rHo: 140 — 145 mm (6.81 —5.71 in) Free play [At pedal pad 1 — 4 mm (0.04 — 0.16 in) Accelerator pedal a . Stroke At pedal pad (46 — 50 mm (1.81 — 1.97 in) 2COMPONENT PARTS crs] 4-5 iH 4. Pedal (MT model} ih 1, Pedal (MT model) 3. LHD TURBO MODEL @ Holder @ Brake pedal ® Assist bushing @ Accelerator bracket ® Clevis pin ‘@ Assist plate ASSY @® Stopper @® Brake pedal spring ® Pedal bracket @® Clip ® Bracket shaft @ Stop light switch © Bushing 4 Cuter pedal pad ® Wave washer © Accelerator spring @ Cuter pedal @ Lover ® Accelerator pedal spring @ Bushing C ———— © Accelerator pedal @ Clip Tightening torque: Nm (ko-m, fb) ® Spring pin @ luton clevis pin TH: 2.2405 (0.224.005, 1.60.4) ® Accelerator pedal pad @ Assist rod 72: 642 (08402, 5.8414) 4) Accelerator stopper @ ‘osit plate A Te Was (18405, 130236) opp eI Te: 202708 +53) ‘Snap pin ® Assist spring A @ Brake pedal pad @® Aosiet spring B 34-5 [ct04) 1. Pedal (MT model) COMPONENT PARTS 4. RHD TURBO MODEL Bushing Accelerator lever Clip Accelerator switch ‘Accelerator pedal ‘Accelerator pedal spring Spring pin Accelerator pedal pad Stopper Spacer Clevis pin Brake pedal pad ® Brake pedal 888OS9GG8000 Snap pin Brake pedal spring Brake spacer Clutch pedal Clutch pedal pad Bushing Clutch pedal bracket Clutch clevis pin Clip Assist rod Assist plate A Assist spring A ® Assist spring B ®QSHOISSISSOS Assist bushing ‘Assiat plato ABSY Pedal bracket Holder Stop light switch Accelerator spring Spring pinSERVICE PROCEDURE twie4] 4-5 1. Pedal cantar Locke nut cuca 1. Pedal ‘A: ON-CAR SERVICE 4, CLUTCH PEDAL (Turbo model) 1) Check clutch pedal free play by operating pedal by hand Free play: L (At clutch pedal pad) 5 — 10 mm (0.20 — 0.39 in) 2) Ifit is out of specification, loosen lock nut for push rod and adjust push rod by turning in the direction that short- ens or lengthens it. Tightening torque (Adjusting nut): 101 Nem (1.00.1 kg-m, 7.2 — 0.7 ft-lb) 3) Check the fluid level on the outside of the clutch mas- ter cylinder tank. If the level is below “MIN”, add clutch fluid to bring it up to “MAX”. Recommended clutch fluid: FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid Pedal free play: L 5 — 15 mm (0.20 — 0.59 in) Pedal height: A 143 mm (5.63 in) Pedal full stroke: B RHD: 145 mm (5.71 in) LHD: 150 mm (5.91 in) B: REMOVAL 4. BRAKE AND CLUTCH PEDAL (LHD turbo model) 1) Remove steering bolts. 2) Raise vehicle on hoist and remove the two bolts which secure steering unit to underside of body. 3) Lower vehicle to floor. 4) Remove instrument panel lower cover from instrument panel. 5) Disconnect the following parts from pedal bracket. © Operating rod of brake booster @ Electrical connectors (for stop lamp switch, etc.) 6) Remove clevis pin which secures lever to push rod. 7) Remove nut which secures clutch master cylinder. 8) Remove steering assembly. 9) Remove bolts and nuts which secure brake and clutch pedals, and remove pedal assembly.4-5 [wiB5] SERVICE PROCEDURE 1, Pedal = 5. CLUTCH PEDAL (RHD turbo model) 1) Remove master cylinder cover. 2) Remove master cylinder mounting nuts. 3) Remove snap pin and clevis pin that join push rod and clutch pedal 4) Remove clutch pedal and bracket as a unit. E: INSTALLATION 3. BRAKE AND CLUTCH PEDAL (LHD turbo model) 1) Set pedal bracket above steering column. 2) Insert bolts of brake booster into holes on toe board, support it from engine room, and fit holes of pedal bracket onto the bolts At this time, operating rod of brake booster should be engaged with brake pedal. 3) While pushing pedal bracket upward firmly, tighten 4 nuts and 2 bolts at its upper surface. 4) Connect operating rod of brake booster to brake pedal using clevis pin and snap pin. @ Clevis pin @ Snap pin @ Operating rod 5) Connect electrical connectors for stop light switch, ete. 6) Install steering column or steering assembly as before. 7) Install nut which secures clutch master cylinder. 8) Install clevis pin which secures lever to push rod ansoasa] 9) Check pedal free play. 4. CLUTCH PEDAL (RHD turbo model) 1) Clean clutch pedal shaft and bushing, and apply grease. 2) Install push rod and clutch pedal with clevis pin and snap pin. 3) Install master oylinder. 4) Install master cylinder cover. 5) Check clutch pedal free play. Refer to ON-CAR SERVICE 4-5 [W1A2]S SPECIFICATIONS... a 1. Air Conditioning System. © COMPONENT PARTS 1. Air Conditioning System 2. Evaporator 3. Compressor W_ SERVICE PROCEDURE. Safety Precautions Basic Information Tools and Equipment. O-ring Connections Refrigerant Service Procedure Discharge the System Evacuating and Charging .. Leak Testing... Lubrication... 10. Performance Test 11, Compressor 12, Condenser 13. Receiver Drier 14. Evaporator 15. Condenser Fan Assembly 16. Flexible Hose 17.Relay and Fuse 18. Pressure Switch (Dual Switch) T DIAGNOSTICS... = ) 1. Air Conditioning System Diagnosis **2, Sight Glass Inspection Performance Test Diagnosis Blower Motor Diagnosis Compressor Diagnosis Compressor Clutch Diagnosis Radiator Fan (Main Fan) Diagnosis Condenser Fan (Sub Fan) Diagnosis (|) Condenser Fan (Sub Fan) Diagnosis (I!) iy esdnagsena ©Enenae *: HALIDE LEAK DETECTOR ([W804}) has been removed. “*: Sight Glass Inspection ((D201]—{0202]) has been removed.4-7 [s100) SPECIFICATIONS 1. Air Conditioning System 1. Air Conditioning System Tem Spectcatons Tipe of ar condtoner Rhea aris ype 5.294 kW A) (4,500 keal/h, 17,856 BTU/h) HFC- tata (CHLFCF.) Aetrgerant (08-07 ¥9 0.3 —15 Ib)) Te Trane rotary, tx volume (CRA) Compressor Discharge 144 cm? (8.79 cu in)irev Max, permissible speed 7,900 rom Type Bry. sinale-diee Wpe Powe consumption ] Magnet clutch Type of bet WAibbes PK Pulley aia, (fesive Wa) 120 (472 Pulley rat Ta moder 111, 18 modal O82 Tee Conpatitntaittw) | Core 0.196 m? (2.1 sq ft) Condenser Core thickness 19 mm (0.75 in) Radiation area 47 (1 2a) Receiver drier Effective inner capacity 250 cm? (15.26 cu in) Expansion valve Te eral equaling Type Single tank Evaporator Bx 270 295 mm Dimensions (W x Hx) on Fan ope Sree fan Blower fan Outer camer x wlth TATE mm 691 x25) Power consumption 20 at 120 olor ype Wagnet a Power consumiion ow at Fan outer damon 380 mm 18.60 im Motor ype Magnet ai Power consump “Bow at 1 Fan outer diameter $20 mm 13.60 in ( BOBO rpm (00:80 rpm 7D" ling speed with F.6D. in operation PFI mode carom 700380 rp 779-00 Low-pressure switch operating heblinalcal (1.80 0.20, 25.5+2.9) Dual switch pressure. kPa (kg/cm?, psi) 18629 (Pressure switch) betaine (1.90+0.30, 27.04 4.2) Tighcpresoureowich operating [ON = OFF Bes 195 QT 2, 04575) pressure KPa ile’, ps) [DIFF [98 632, 05128) Compressor rl valve Blowout pressure Ka Galen? pel 7a 196 08:42, 640.95) ot 15405%0 @s:z08") ‘Thermo control amplifier working temperature ‘ON (Evaporator outtt air) oF Sassy sone) ss 140+ 5°C (2849°F) Compressor thermocut temperature omeSERVICE PROCEDURE (wi0z] 4-7 Safety Precautions 1. Safety Precautions 1. HFC-134a AIR CONDITIONING SYSTEM Component parts of the cooling system, refrigerant, com- pressor oil, and other parts are not the same for the HFC- 184a system and the older CFC-12 system. Do not inter- change parts or liquid. Vehicles with HFC-134a air conditioning systems, use only HFC-134a parts that are indicated on a label attached to the vehicle. Before performing any maintenance, verify the type of air conditioning system installed in the vehicle. HFC134a use FOR HFC134a GD SUBARU oovourm —[SAUTION: me areca wes moon mn P os as Conoen. SOT URE EGAN FE A AR CONDTIONER (TYPE) oman =| REFRIGERANT CHARGE: ‘REFRIGERANT UNDER HIGH PRESSURE. | ATTENTION: uruisez ut uowoe nérmstaan Wrct34s ® | eine 2 0705-09 CGNSIL SERVICE WNL cis nm ul cnn wea UENCE SReRSSR eT: mrowmeay — Sesto | VORSICHT: waa wr oe ag nn Tamrac 184) SHE 1683 ina ortsaee A Tee 2 cenasra} 2. COMPRESSOR OIL Do not use any compressor oil that is not specifically designated for the HFC-134a air conditioning system; only use DH-PR. Also, do not use HFC-134a compressor oil in the CFC-12 air conditioning system. if compression oils are mixed, poor lubrication will result and the compressor itself may be damaged. Because HFC-134a compressor oil is very hygroscopic (easily absorbs moisture), when parts of the air condition- ing system are being removed, quickly install a blind plug to prevent contact with the outside air. Also, always make sure that the service container for compressor oil is tightly closed except when in use. Store compressor oll in a tightly closed steel container.4-7 [w103] 1, Safety Precautions, Goggles ‘Avoid open sf ty Gloves No direct host ‘on container Do rot discharge SERVICE PROCEDURE 3. REFRIGERANT Do not put CFC-12 refrigerant into a HFC-134a air condi- tioning system. Also, do not put HFC-134a refrigerant into a CFC-12 air conditioning system. if the wrong refrigerant is used, poor lubrication will result and the compressor itself may be destroyed 4. HANDLING OF REFRIGERANT Because refrigerant boils at approx. -30°C (-22°F) at sea level, it is cold enough to give you severe frostbite. Always wear goggles to protect your eyes and gloves to protect your hands. Also, even under the pressures normally found in CFC-12 containers, refrigerant will boil with the addition of heat. This could raise the pressure inside the container to a dangerous level Never expose a can of HFC-134a to direct sunlight, or to temperatures over 40°C (104°F). One more thing to remmem- ber about HFC-134a is that when it is exposed to an open flame or to hot metal, it forms phosgene, a deadly gas. Do not discharge HFC-134a into the atmosphere on purpose. Always read and follow the precautions on the HFC-134a bottle.SERVICE PROCEDURE [W300] 4-7 3. Tools and Equipment \ 3. Tools and Equipment The following section provides information about the tools and equipment that will be necessary to properly service the A/C system, Since equipment may vary slightly depending on the manufacturer, it is important to always read and follow the manufacturer's instructions CAUTION: When working on vehicles with the HFC-134a system, only use HFC-134a specified tools and parts. Do not mix with CFC-12 tools and parts. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, poor lubrication will result and the compressor itself may be destroyed. In order to help prevent ig HFC-134a and CFC-12 parts and liquid, the tool and screw type and the type of service valves used are different. The gas leak detec- tors for the HFC-134a and CFC-12 systems must also not be interchanged. HFO-194a, oFo-12 Tool & screw type Millimeter size Inch size Valve type Quick joint ype Screw-in type Tools and Equipment Description WRENCH Various WRENCHES will be required to service any AIC system, A 7 to 40 Nem (0.7 to 4.1 kg-m, § to 20 fLib) torque ‘wrench with various crowtoot wrenches will be needed. Open ‘end of flare nut weenches will be needed for back-up on the tube and hose fittings oor ‘ APPLICATOR BOTTLE ‘A small APPLICATOR BOTTLE is recommended to apply fefrigerant oil to the various parts, They can be obtained at a hardware or drug store. ews4-7 (ws00) SERVICE PROCEDURE 3, Tools and Equipment ‘Tools and Equipment Description ‘@ MANIFOLD GAUGE SET [A MANIFOLD GAUGE SET (with hoses) can be obtained from either a commercial refrigeration supply house or from an auto shop equipment supplier. comers ‘> REFRIGERANT RECOVERY SYSTEM A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A/C system refrigerant after ‘contaminants and moisture have been removed from the refrigerant [> SYRINGE AA graduated plastic SYRINGE will be needed to add oil back into the system, The syringe can be found at a pharmacy or drug store, coms ‘= VACUUM PUMP ‘A VACUUM PUMP (in good working condition) is necessary, ‘and may be obtained from either a commercial refrigeration ‘supply house or an automotive equipment supplier. coumSERVICE PROCEDURE [W300] 4-7 3. Tools and Equipment Tools and Equipment Description = CAN TAP [ACN TAP for the 397 g (14 02) can is available trom an ‘auto supply store. oxnosr7 ~» THERMOMETER Pocket THERMOMETERS are available from either industrial hardware store or commercial refrigeration supply houses, coos ~ ELECTRONIC LEAK DETECTOR An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A/C equipment suppl ‘© WEIGHT SCALE ‘A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed if a 13.6 kg (90 1b) refrigerant container is used. coomesea4-7 w702} SERVICE PROCEDURE Lowpressure gauge (Compound prossure ‘gauge? aston 7. Evacuating and Charging 2. PERFORM A VACUUM LEAK TEST 1) After 15 minutes (or more) of evacuation, close the high-pressure manifold valve. 2) Close the low-pressure manifold valve 3) Turn off the vacuum pump. 4) Note the low side gauge reading 5) After 5 minutes, re-check the low-pressure gauge read- ing. If the vacuum level has changed more than 4 kPa (25 mmHg, 1 inHg), perform an HFC-134a leak test. If the vacuum reading is about the same as noted in step 2-4), continue on to step 2-6) 6) Carefully attach the can tap to the refrigerant can by following the can tap manufacturer's instructions. 7) Disconnect the center manifold hose from the vacuum pump and connect the hose to the tap valve. 8) If a 13.46 kg (30 Ib) container of refrigerant is used a weight scale will be needed. This scale is to determine the amount of refrigerant that is used Connect the center hose from the manifold to the valve. Place the 13.6 kg (30 Ib) container on the scale, valve end down. 3. PURGE THE CENTER HOSE 1) Verify that all three hose connections are tight at the manifold gauge set. 2) Open the valve on the HFC-134a source. 3) With safety equipment in place (goggles and gloves), use extreme caution and loosen the center hose con- nection at the manifold and allow the HFC-134a to escape for no more than two or three seconds, then quickly retighten the hose fitting at the manifold. 8 —iSERVICE PROCEDURE tw70s] 4-7 7. Evacuating and Charging 5. CHECK THE GAUGE READINGS When both the high- and low-pressure gauge readings are about equal, or the HFC-134a source is empty, or the system has been filled to specifications, close the high- pressure manifold valve. 6. ADD ADDITIONAL CANS If the HFC-134a source is exhausted, first close the high- pressure manifold valve, second, close the can tap valve, then slowly purge the refrigerant from the service hose by loosening the fitting at the can tap. Repeat steps 15 through 19 as necessary. 8. CHARGE THE SYSTEM 1) With the refrigerant source connected and the service hose purged, slowly open the low-pressure manifold valve, while checking the low-pressure gauge reading. CAUTION: The refrigerant source must be positioned for vapor (valve up). 2) Keep the low side pressure below 276 kPa (2.81 kg/cm?, 40 psi) by using the low-pressure manifold valve to regu- late the flow of refrigerant into the system. 3) When the system is fully charged, close the low- pres- , sure manifold valve, 4) Close the valve at the refrigerant source. | @ Refrigerant capacity Unit kg (to) | Refrigerant Minimum Maximum HEC-948 06 (13) 07 (15)4-7 [ws05] SERVICE PROCEDURE 8. Leak Testing 8. Leak Testing 5. LEAK TEST — HIGH-PRESSURE SIDE Operate the A/C system for approx. 10 minutes, then turn the engine off and begin the leak test. 1) Begin at the connection of the high-pressure tube to the evaporator, and work your way along the high- pres- ‘sure side of the system to the compressor. There are three places to check each tube connection. cawer2] 2) Check the area. (1) Check the area where the fitting meets the tube. (2) Check the area where the two parts of the fitting join each other. atts (3) Check the area where the nut meets the tube. ( 3) Check the area of the pressure switch (dual switch), and also check the seams of the receiver drier. 4) Check the connections of the tubes to the condenser, and also check any welded joints on the condenser. caUTIO An oily on the fins of the condenser may indicate a leak. 5) Check the area where the hoses attach to the com- pressor. 10 4SERVICE PROCEDURE (wisao] 4-7 8. Leak Testing - 18. Pressure Switch (Dual Switch) 6) Check around the machined portions of the compres- sor (where the compressor sections join each other) 7) If equipped, check the thermal limiter on the compres- sor housing, 8) Check the compressor shaft seal by probing near the center of the compressor clutch pulley. NOTE: Some shaft seals have a very slight amount of normal leakage [approximately 28 g (1.0 02) per year] 9. Lubrication 3. OIL REPLACEMENT ‘After stabilization and discharge, replace the component, adding the appropriate amount of oil (DH-PR) to the new component before installation. ) Era Tmt G9 0S en ined Receiver drier S mt (02 US N oz, 02 imp fl o2) Condenser 2 me (0.07 US fi oz, 0.07 Imp fl oz) Hose ‘Tmt (003 US 1 oz, 0.08 imp fez) If the compressor is replaced (after stabilization): 1) Drain and measure the oil from the original compres- sor. 2) Drain the oil from the replacement compressor and refill with the same amount that was drained from the original [20 me (0.7 US fl 02, 0.7 Imp fl oz) minimum} Always use DH-PR for the replacement oil 18. Pressure Switch (Dual Switch) A: INSPECTION y 1) Remove cap from high-pressure line service valve, and connect gauge manifold to service valve, 2) Disconnect pressure switch harness connector, and check pressure switch for proper ON-OFF operation. Use a circuit tester. High-pressure side line pressure Terminal Operation kPa (kgfem?, psi) Increasing to 2,648: 196 (27 42, 984.428) Decreasing to High and low pressure 177 £20 (1.8402, 2642.8) switch Increasing to 186429 (1.90.3, 27:44) Decreasing to 2,059: 196 (21 42, 209+ 28) Turns OFF, Turns ON. "4-7 [r100} DIAGNOSTICS 1. Air Conditioning System Diagnosis 1. Air Conditioning System Diagnosis — oO eet a tw rma tom C = a ae sure,

ryreasue fea [wnwsrerew «i teteoinn [Ar mims or [ Sece e drier. 3, Evacuate and ‘charge system. canoer MOITURE Sate ‘Atter operation for a | Drier i saturated with |1. Discharge system while, pressure on | moisture. Moisture |2. Replace receiver suction side may show |has frozen at expan- | drier (twice if neces : vacuum pressure | sion valve. Refrigerant | sary). Low-pressure High-pressure | eading. During this |flow is restricted 3. Evacuate system ‘gauge page ‘condition, discharge completely. (Repeat 90 alr will be warm. As minute evacuating ‘warning of this, read- three times.) ing shows 39 kPa (0.4 4, Recharge system kgiem?, 6 psi) vibra- tion 14 _éADIAGNOSTICS (7300) 4-7 3, Performance Test Diagnosis Condition Probable cause Corrective action FAULTY CONDENSER, High-pressure [No cooling action Engine may overheat ‘Suction line Is very hot. Condenser is often found not functioning well Je Check condenser cooling fan. Je Check condenser for dirt accumulation ‘¢ Check engine cool- ing system for over- heat 1¢ Check for retriger ant cvercharge, 1M pressure remains high in spite of all above actions taken, remove and inspect the condenser for pos- sible of clogging. Low-pressure High-pressure gauge Ingutficient cooling, Frosted high-pressure liquid line. Drier clogged, or restriction in high- pressure line, 4, Discharge system. 2. Remove receiver drier o* strainer and replace it. 3, Evacuate and charge system. FAULTY COMPRESSOR cose Insufficient cooling, Internal problem in ‘compressor, or dam- aged gasket and valve. 1, Discharge system }2. Remove and check Jcompressor. 3. Repair oF ro [compressor. 4. Cheek oil level 5. Replace receiver drier 6. Evacuate and charge system, 15